Case Studies
Sustainable Construction with eMesh at the Transport for NSW’s New Intercity Fleet Maintenance Facility
Sustainable Construction with eMesh at the Transport for NSW’s New Intercity Fleet Maintenance Facility
92% CO₂
Emissions reduced
20%
Cost saved
Steel mesh
Placement eliminated
Plastic waste
Diverted from the landfill
Project Summary
John Holland’s New Intercity Fleet Maintenance Facility on the Central Coast of NSW embraced sustainable innovation by trialling new materials to reduce environmental impact. The project prioritised efficient material use, minimised waste through effective planning, and aligned with the company’s commitment to greener construction practices. The facility team used this initiative to test alternative solutions that could shape future infrastructure delivery in Australia.
Use of eMesh
A significant innovation in the project was the use of eMesh as a replacement for traditional steel reinforcement in 2,739m² of footpath concrete. While eMesh has been deployed in Queensland, this was its first use on a Roads and Maritime Services asset in NSW. Its application in non-structural concrete (e.g., footpaths, cycleways, islands) offered a faster, more cost-effective, and environmentally friendly alternative to steel.
Benefits
- 92% reduction in carbon emissions vs conventional steel
- 20% cost savings
- Eliminated need for steel placement—reducing time and improving safety
- Diverts plastic waste from landfill
- Now preferred by asset owners for similar applications
Above information is based on the Sustainability Report 2019 published by John Holland.
The Palm Island Infrastructure Upgrade
The Palm Island Infrastructure Upgrade
24 Tonnes
Recycled Plastic reused
9,200 m³
Water saved
500 Tonnes
CO₂ saved
120 Tonnes
Fossil fuel saved
Project Summary
Palm Island, off the coast of North Queensland, is home to over 2,000 people, primarily Indigenous Australians. The community faces chronic infrastructure challenges, particularly in its 30 km road network, which deteriorates annually due to tropical monsoons and inadequate drainage. Historically underfunded and unable to raise revenue locally, the Palm Island Aboriginal Shire Council proposed replacing its bitumen roads with more durable concrete.
Use of eMesh
The Council adopted eMesh as an alternative to conventional steel mesh reinforcement in concrete. eMesh offered improved durability in Palm Island’s corrosive coastal environment, reduced transport and labour costs, and simplified recycling processes. It also enabled safer, faster construction and allowed locals to be trained and employed in its use, contributing to community development.
Benefits
- Recycled Plastic: 24 tonnes reused as reinforcement
- Water Saving: 9,200 m³ saved – enough to fill 4 Olympic pools
- Carbon Impact: 500 tonnes CO₂ saved – equivalent to removing 110 cars for a year
- Fossil Fuel: Over 120 tonnes saved
- Concrete Recycling: 17,000 tonnes processed, saving $1.5 million in materials
Recognitions
- Finalist in Qld Environment & Sustainability Awards: This innovative approach presents a scalable model for remote and coastal communities across Australia and the Pacific.
Above information is based on the full case study/article published by the The Palm Island Infrastructure Upgrade
MRPV and RPV Adopt eMesh for Victoria’s Big Build Projects
MRPV and RPV Adopt eMesh for Victoria’s Big Build Projects
Over 90% CO₂
Emission reduced
Over 90%
Water saved
Project Summary
Major Road Projects Victoria (MRPV) and Rail Projects Victoria (RPV), in partnership with the North Western Program Alliance (NWPA), have adopted eMesh for ongoing use across Victoria’s Big Build infrastructure programme. First trialled successfully in the Bell to Moreland Level Crossing Removal Project (B2M LXRP), eMesh is now standard in sustainable construction of shared user paths (SUPs) and footpaths, streamlining processes and reinforcing the state’s commitment to innovation in environmentally responsible construction.
Use of eMesh
eMesh replaced traditional steel mesh in concrete reinforcement. Its adoption followed a rigorous approval process, involving site inspections, environmental assessments, and extensive stakeholder engagement. Its integration reduced construction risks, simplified logistics, and improved site efficiency—removing the need for steel handling and associated inspections.
Benefits
- Over 90% reduction in CO₂ and PO₄ emissions.
- Over 90% savings in water usage and fossil fuel consumption.
- Significant reuse of waste plastic, contributing to circular economy goals.
- Improved on-site safety by eliminating the need to handle and install steel mesh.
- Reduced construction time and labour costs due to simplified logistics.
- Minimised inspection requirements, as eMesh eliminates pre-pour steel checks.
- Ongoing benefits expected across future Big Build projects through efficiency, sustainability, and cost-effectiveness.
Above information is based on the full case study/article published by the Infrastructure Sustainability Council. Read the article eMesh concrete steel mesh replacement.
Australian Grand Prix Corporation wins sustainability award
Australian Grand Prix Corporation wins sustainability award
Project Summary
The Australian Grand Prix Corporation (AGPC) was awarded the 2022 #SEAChanger Award by the Sports Environment Alliance for its groundbreaking Green Prix initiative. This sustainability-focused program, launched alongside the return of Formula 1® to Albert Park in 2022, introduced numerous environmental strategies including food donation schemes, waste reduction efforts, increased green space, and infrastructure powered by renewable energy. The five-year Green Prix Strategy aligns with environmental goals set by Formula 1®, the Victorian Government, and the United Nations SDGs, signalling a long-term commitment to sustainable event delivery.
Use of eMesh
A key innovation in the project was the use of eMesh. It was incorporated into the construction of the Australian Grand Prix broadcast area at Albert Park. Chosen for its strong environmental credentials, eMesh contributed significantly to lowering the event’s carbon footprint by providing an eco-friendly, high-performance building material solution.
Benefits
- eMesh used in key infrastructure
- 90% reduction in CO₂ emissions compared to steel mesh
- Water savings through reduced construction material demand
Above information is based on the full case study/article published by the Australian Grand Prix Corporation. Read the article Australian Grand Prix Corporation wins sustainability award.
Cairns Southern Access Corridor Stage 3
Cairns Southern Access Corridor Stage 3
3X Faster
Construction
16 Tonnes
Recycled Plastic used
1,400 Tonnes
CO₂ saved
115 Tonnes
Steel mesh replaced
Project Summary
This $535 million project delivered significant safety improvements along this section of the Bruce Highway, which is the busiest 2-lane section of the Bruce Highway between Brisbane and Cairns. This project made travelling safer for motorists, cyclists and pedestrians and improved flood resilience for North Queensland.
The first initiative involved constructing over 10 km of concrete pavements for cycleways, footpaths, and shared paths using a Concrete Extruding Slipform Paver with a custom mould and our fibres reinforcement.
Use of eMesh
“This Australian-first method was developed by E2G in conjunction with the project’s concrete supplier, Enviromesh and Department of Transport and Main Roads and resulted in a reduction of raw materials consumption, significantly increased productivity, enhanced personnel safety, and supported waste repurposing. The slipform paver was used to mechanically place the concrete during pavement construction, reducing project construction times and lowering GHG footprints. Enviromesh’s fibre reinforced concrete solution aligns with circular economy principles, repurposing waste into new products, diverting waste from landfills, and strengthening the market for sustainable materials.”
Benefits
- From 250 m2/day to 1050m2/day construction combining eMesh and slip form paver enabled 3X faster construction
- 16t of synthetic fibres made with recycled plastic was used
- 1,400t CO2e reduced resulting in 75% less emissions by combining eMesh, slip form paver and hybrid solar system
- 115t of steel mesh reinforcement replaced
- 25% cost savings – Approximately $12/m2 less compared to steel mesh reinforced concrete construction
- 85% or ≈ 75,000L fossil fuel saved
Above information is based on the full case study/article published by Infrastructure Sustainability Council (ISC). Read the article Cairns Southern Access Corridor Stage 3: Edmonton to Gordonvale Project – Environmental Outcomes.
Level Crossing Removal Projects (LXRP)
Level Crossing Removal Projects (LXRP)
30 Tonnes
Steel mesh replaced
Over 90% CO₂
Emission reduced
Over 90%
Water saved
Project Summary
With an estimated cost of $18 billion, LXRP is an infrastructure upgrade program by the Government of Victoria, Australia, to remove and grade-separate 110 level crossings and to rebuild 51 railway stations on the metropolitan rail network of the state capital Melbourne.
eMesh fibres are used in more than 40 LXRP projects that are either near completion or have completed. Below snapshot showcases benefits derived in construction of a small section in this mega project.
Use of eMesh
“The widespread use of steel in concrete releases large quantities of carbon into the atmosphere. Also, steel used in concrete can often corrode, which can significantly reduce its lifespan. As a solution we added eMesh to the concrete used in footpaths and cycling paths on our sites. Recycled plastic or macro synthetic fibre also known as eMesh is an environmentally sustainable alternative to steel mesh reinforcement or virgin polypropylene fibres. eMesh arrives on site already mixed into the concrete, reducing costs. The use of 100 per cent recycled fibres also doesn’t require steel cutting and tying, improving safety.” LXRP Sustainability Snapshot – June 2023
Benefits
Around 4.2 tonnes of our sustainable fibres replaced 30 tonnes (712 sheets) of steel mesh in construction of shared used paths between just two stations – Bell to Moreland. To put the numbers in perspective the savings derived by replacing steel mesh just for a few sites translates as below:
- 90% reduction in carbon emissions compared to steel mesh
- 90% reduction in water consumption during manufacturing process
- At least 106.4t of carbon emission saved for some of the sites listed
- Equivalent to 582,000km driven by an average vehicle for a year
Project Sites
- Cranbourne Line Upgrade
- Manchester Road, Mooroolbark
- Maroondah Highway, Lilydale
- Bell to Moreland
- Glenroy Road, Glenroy
Above information is based on the full case study/article published by the Major Transport Infrastructure Authority, Victoria on the Big Build Victoria website. Read the article LXRP Sustainability Snapshot June 2023.
Mordialloc Freeway
Mordialloc Freeway
17 Tonnes
Recycled fibres used
Over 90% CO₂
Emission reduced
106.4 Tonnes
CO₂ emission saved
Over 90%
Water saved
Project Summary
The $523 million Mordialloc Freeway project aimed to reduce traffic delays by trimming 10 minutes off a trip between the Mornington Peninsula Freeway and the Dingley Bypass. The project involved the construction of 9 kilometres of freeway, 6 bridges, and 8 kilometres of walking and cycling paths. The Mordialloc Freeway was awarded the highest sustainability rating ever given to any Australian infrastructure project. It garnered several prestigious sustainability awards for its innovative use of recycled materials and materials with a lower carbon footprint. It is dubbed the world’s greenest freeway project. By replacing steel mesh in the construction of almost 8km-long Shared Walking and Cycling Paths constructed along the entire length of the freeway, Enviromesh fibres played a pivotal role in reducing the carbon footprint of this widely applauded project.
Use of eMesh
“Running parallel to the freeway is the 7,700 lineal metres of shared use path (SUP) developed for community use. This SUP was constructed from concrete with >30% Portland Cement replacement (Supplementary cementitious materials – slag and fly ash), and 100% recycled plastic fibre reinforcement (a Victorian first innovation on a major road project). The project used approximately 17 tonnes of recycled plastic fibres (eMesh) made from industrial offcut waste. Using sustainable materials in the SUP saved approximately 400 tonnes of greenhouse gas emissions compared to typical construction materials.”
Benefits
- 17t of synthetic fibres made with recycled plastic was used
- 90% reduction in carbon emissions compared to steel mesh
- 90% reduction in water consumption during manufacturing process
- At least 106.4t of carbon emission saved for some of the sites listed
- Equivalent to 582,000km driven by an average vehicle for a year
Above information is based on the technical paper published by Engineers Australia. Read the article Australian Construction Achievement Award Mordialloc Freeway Technical Paper.
Transport Canberra adopts eMesh
Transport Canberra adopts eMesh
Supports plastic
Waste reduction
Up to 90%
Carbon emissions reduced
Project Summary
Transport Canberra and City Services (TCCS) has integrated eMesh into its path network improvements project. This decision follows a successful trial in 2020–2021, initiated to explore environmentally friendly alternatives to steel in community path construction. A four-year monitoring plan was established to evaluate eMesh’s performance across various sites, with findings expected to guide long-term infrastructure planning and standards.
Use of eMesh
TCCS’s trial involved 1,000 m² of eMesh-reinforced paths, aiming to test durability, sustainability, and recyclability. eMesh enables faster, safer construction and offers the potential for end-of-life recyclability, including re-use in road base blends or further plastic recovery through washing plants.
Benefits
- Up to 90% reduction in carbon emissions compared to traditional steel reinforcement.
- Potential for full recyclability at end-of-life, including re-use in road base blends.
- Comparable cost to steel reinforcement, making it a viable sustainable alternative.
- Water savings through reduced energy and resource use in manufacturing processes.
- Encourages local recycling industry development through testing and collaboration.
- Improves construction safety and efficiency with lighter, easier-to-handle materials.
Above information is based on the article/case study published on the ACT Government website under Infrastructure Projects and the Annual Report 2021 – 2022 (Page 100)
Reducing Cross River Rail’s carbon footprint
Reducing Cross River Rail’s carbon footprint
120,000 Fibre per
Cubic metre of concrete
Reduced
Carbon emissions
Project Summary
The Cross River Rail project in Queensland has taken a pioneering step by incorporating eMesh, a recycled plastic fibre reinforcement in concrete works at the new Mayne Yard North stabling facility. As a first for the state’s rail network, this initiative reflects a strong focus on sustainability and innovation in infrastructure development. The wider project also showcases a broad commitment to recycling and waste reuse, with a significant proportion of spoil being repurposed for brick manufacturing and construction materials.
Use of eMesh
eMesh replaced conventional steel reinforcement in this project. Each cubic metre of concrete contains over 120,000 fibres, delivering strength while reducing the need for cutting and handling. The reusable fibres supported the environmental goals of the project.
Benefits
- Over 120,000 fibres per cubic metre of concrete
- Reduced carbon emissions compared to steel reinforcement
- Reduced water use in concrete production
- Less manual handling, improving onsite safety
- Support for 90 jobs via NDIS-supported fibre packaging
Above information is based on the article published on the Cross River Rail website. Read the article Cross River Rail embraces fantastic plastic solution.
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Send us a message
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Need more information?
We are here to assist you. Our team is committed to providing the support and information you require.
You can also connect with us on LinkedIn or download important documents from the links below.
Request EPD
Environmental Product Declaration
Request TMSDS
Technical and Material Safety Data Sheet
Send us a message
Or please feel free to reach out via phone or email using the details below.